Thread breakage detection systems amd methods

ABSTRACT

A thread breakage detection apparatus comprises a light source operable to generate a light beam, an emitter in communication with the light source, the emitter operable to emit the light beam, and a receiver in communication with and disposed in facing opposition to the emitter, the receiver operable to receive the light beam emitted from the emitter and to communicate the light beam to a sensor. The emitter comprises an emitter lens and a first fiber optic cable comprising proximate and distal ends. The proximate end of the first cable in communication with the light source and the distal end of the first cable in communication with the emitter lens. The receiver comprises a receiving lens and a second fiber optic cable comprising proximate and distal ends, the proximate end of the second cable in communication with the receiving lens and the distal end of the second cable in communication with the sensor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S. patentapplication Ser. No. 10/644,485, filed Aug. 20, 2003, entitled “ThreadBreakage Detection Systems and Methods,” the entirety of which is herebyincorporated by reference.

FIELD OF INVENTION

This invention relates to products and processes for detecting threadbreakage in a sewing apparatus.

BACKGROUND

A sewing apparatus operates by piercing fibers or threads into a basefabric with needles. A sewing apparatus typically includes a needlewhich receives thread through its eye from a source of thread which maybe mounted on the body of the sewing machine or remotely therefrom. Thethread generally follows a path through various thread guides or guideplates on the machine, through a thread tensioning device, a threadtake-up device, and then through other guide means mounted above theneedle. The thread is then directed through the eye of the needle. Thetake-up device pulls the thread tight between the needle and the threadtensioning device. While the sewing apparatus is in operation, athreaded needle moves in a reciprocal fashion and continually insertsthread into a passing base fabric.

An example of a sewing apparatus includes a carpet tufting apparatushaving a needle bar carrying a plurality of needles for inserting yarnscarried by said needles into a base fabric for producing loops of yarns.The loops of yarns can be formed into loops of different heights or cutto form cut loop carpet.

A common problem associated with any sewing apparatus is the detectionof thread breakage during operation before the broken thread is sewn orinserted into the base fabric. For example, during the carpet tuftingprocess, when one of the multitude of yarns breaks while the carpettufting apparatus is in operation, the eventual absence of thread in thecorresponding needle creates a gap defect, or “mend,” in the carpet. Arelatively short mend, such as less than 0.5 meters, in a carpet samplecan be corrected using a hand-held device, but longer mends are muchmore difficult—or even impracticable—to fix. Thus, yarn breakage oftenresults in carpet waste, which increases the ultimate cost ofproduction.

To reduce the length of a mend, reduce the number of mends, or preventmends in a sewing article, the sewing apparatus must stop operating assoon as possible after a thread breaks. Various types of thread breakagemonitoring devices have been developed for stopping a sewingapparatus—or at least providing a warning signal—after thread breakagehas been detected.

A variety of optical devices have been used in an attempt to effectivelydetect thread breakage. Two examples of such devices can be found inU.S. Pat. Nos. 4,625,666 to Sick and 4,691,647 to von Stein. Generally,such devices attempt to detect thread breakage by projecting a lightbeam near or onto the threads of a sewing apparatus. These devices aretypically grouped into two categories: light-on and dark-on. When athread breaks and either falls into (dark-on) or out of the light beam(light-on), a photo-sensor detects a change in the light beam and sendsa signal to a controller or alarm indicating thread breakage.

In typical dark-on optical sensing systems, a light beam is positionednear a thread or a bank of threads such that a photo-sensor receives agenerally continuous beam of light while the threads are intact. When athread breaks and passes or falls through the path of the light, thethread temporarily interrupts the light beam. The photo-sensor detectsthis interruption in the light beam—i.e., a quantity of light lower thana predetermined threshold quantity of light—and sends a signalindicating that the light beam has been interrupted or broken.

The closer the light beam is positioned to a thread, the greater thelikelihood a broken thread will interrupt or fall through the lightbeam. To position the light beam closely to the thread normally requiresthat the optical device be attached or mounted directly to the sewingapparatus. The size of known thread breakage detection devices—inparticular the photo-sensor emitters and receivers of thesedevices—prevents placement of the light beam in positions near thethreads, which would help ensure or increase the consistency of threadbreakage detection.

Further reducing the accuracy and consistency of thread breakagedetection is the vibration typical of sewing apparatuses. Vibration ofsewing apparatuses—especially those used on an industrial scale—iscommon. Such vibration often jars the light emitter and/or receiver ofthe optical thread breakage detection device out of alignment. Not onlydoes such misalignment interrupt the production process, butmisalignment can often be difficult to detect, resulting in menddefects.

Known optical thread breakage detection systems also require precisealignment to consistently and accurately detect thread breakage. Machinevibration further reduces the accuracy and consistency of such systems.Thus, there is a need for an optical thread breakage detection apparatusthat can be positioned near the thread of a sewing apparatus and thatalso is generally less susceptible to misalignment caused by machinevibration.

SUMMARY OF INVENTION

The present invention provides products and processes for detectingthread breakage in a textile sewing apparatus. In one exemplaryembodiment, a thread breakage detecting apparatus adapted to be coupledto a textile sewing apparatus comprises a light source, an emitter, anda receiver. The light source is operable to generate a light beam. Theemitter is disposed in communication with the light source. The emitteris operable to emit the light beam. The emitter comprises an emitterlens and a first fiber optic cable. The fiber optic cable comprisesproximate and distal ends. The proximate end of the first fiber opticcable is disposed in communication with the light source and the distalend of the fiber optic cable disposed in communication with the emitterlens. The receiver is disposed in communication with the emitter. Thereceiver is operable to receive the light beam and to communicate thelight beam to a sensor. The receiver comprises a receiving lens and asecond fiber optic cable. The second fiber optic cable comprisesproximate and distal ends. The proximate end of the second fiber opticcable is disposed in communication with the receiving lens and thedistal end of the second fiber optic cable is disposed in communicationwith the sensor. The receiving lens is disposed in facing opposition tothe emitter lens.

In another exemplary embodiment, a system comprises a textile sewingapparatus and a thread breakage detection apparatus coupled to thetextile sewing apparatus. The thread breakage detection apparatuscomprises a light source, an emitter, and a receiver. The light sourceis operable to generate a light beam. The emitter is disposed incommunication with the light source. The emitter is operable to emit thelight beam. The emitter comprises an emitter lens and a first fiberoptic cable. The fiber optic cable comprises proximate and distal ends.The proximate end of the first fiber optic cable is disposed incommunication with the light source and the distal end of the fiberoptic cable disposed in communication with the emitter lens. Thereceiver is disposed in communication with the emitter. The receiver isoperable to receive the light beam and to communicate the light beam toa sensor. The receiver comprises a receiving lens and a second fiberoptic cable. The second fiber optic cable comprises proximate and distalends. The proximate end of the second fiber optic cable is disposed incommunication with the receiving lens and the distal end of the secondfiber optic cable is disposed in communication with the sensor. Thereceiving lens is disposed in facing opposition to the emitter lens.

In a further exemplary embodiment, a method of detecting thread breakagein a textile sewing apparatus comprises providing a light sourceoperable to generate a light beam, providing an emitter operable to emitthe light beam, and providing a receiver operable to receive the lightbeam and to communicate the light beam to a sensor. The emittercomprises an emitter lens and a first fiber optic cable. The first fiberoptic cable comprises proximate and distal ends. The proximate end ofthe first fiber optic cable is disposed in communication with the lightsource and the distal end of the fiber optic cable is disposed incommunication with the emitter lens. The receiver comprises a receivinglens and a second fiber optic cable. The second fiber optic cablecomprises proximate and distal ends. The proximate end of the secondfiber optic cable is disposed in communication with the receiving lensand the distal end of the fiber optic cable is disposed in communicationwith the sensor. The receiving lens is disposed in facing opposition tothe emitter lens.

An advantage of the present invention can be to provide a threadbreakage detection apparatus that is adapted to be disposed proximate,i.e., within several millimeters, to a thread disposed in a textilesewing apparatus.

Another advantage of the present invention can be to provide a threadbreakage detection apparatus that is adapted to be less susceptible tomisalignment resulting from machine vibration.

Yet another advantage of the present invention can be to provide athread breakage detection apparatus that is adapted to operate withoutprecise alignment between a light emitter and a light receiver.

Still another advantage of the present invention can be to provide athread breakage detection apparatus that is adapted to detect threadbreakage spanning a distance in a range between approximately 1 meter toapproximately 4 meters.

These exemplary embodiments are mentioned not to summarize theinvention, but to provide an example of an embodiment of the inventionto aid understanding. Exemplary embodiments are discussed in theDetailed Description, and further description of the invention isprovided there. Advantages offered by the various embodiments of thepresent invention may be understood by examining this specification.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which constitute part of this specification,help to illustrate the embodiments of the invention. In the drawings,like numerals are used to indicate like elements throughout.

FIG. 1 shows a schematic of a prior art sewing apparatus.

FIG. 2 shows a schematic of an embodiment of a system according to thepresent invention.

FIG. 3 shows a schematic of a thread breakage detection apparatusaccording to an embodiment of the present invention.

FIG. 4 shows a block diagram of a method according to the presentinvention.

DETAILED DESCRIPTION

Embodiments of the present invention comprise products and processes fordetecting thread breakage in a textile sewing apparatus, such as forexample, in a carpet tufting machine. While the present invention isdescribed herein as a dark-on through-beam detector, the principles ofthe invention are applicable to light-on detectors. Furthermore, theprinciples of the invention are not limited to through-beam detectors.

Referring now to FIG. 1, a schematic of a prior art carpet tuftingapparatus 10 is shown. A needle bar 11 is coupled to a needle 12. Athread 13 is guided through a bore 14 disposed in a yarn guide plate 15.In industrial carpet tufting machines, it is not uncommon to haveapproximately 1800 individual strands of thread or yarn guided throughseveral yarn guide plates each spanning several meters. For purposes ofillustration and to facilitate understanding of the invention, however,only a single needle 12 and thread 13 are shown and described.

The needle 12 of the carpet tufting apparatus 10 is shown in theuppermost position of the needle stroke. The thread 13 is guided throughbore 14 disposed in yard guide plate 15 above the needle bar 11 andobliquely downwardly to the eye 16 of the needle 12 from where thethread 13 extends into a backing material 17 of the tufted product. Theneedle bar 11 is secured to a suitable stroke member (not shown) andreciprocates and moves downwardly whereby the needle 12 penetrates thebacking material 17. Tufting machines are well known, and thus a moredetailed description will not be provided herein.

Referring now to FIG. 2, a schematic of system according to anembodiment of the present invention is shown. The system includes atextile sewing apparatus 20, which is shown in a schematic view. In oneembodiment, the textile sewing apparatus comprises a carpet tuftingapparatus. Alternatively, other suitable textile sewing machines can beused. Thread 23 is supplied to the carpet tufting machine 20 from a yarnsupply, such as a creel 24. The thread 23 passes through a plurality ofyarn guide plates 25. A yarn feed mechanism 26 includes four rollers 26a, 26 b, 26 c, and 26 d over which the thread 23 passes successively,past a needle bar 21 and then to the needle (not shown) and into abacking material (not shown). The rollers 26 a, 26 b, 26 c, and 26 d aresynchronized with each other to feed the thread and are controlled by asynchronous motor.

A thread breakage detection apparatus 30 is coupled to the textilesewing apparatus 20. Preferably, a plurality of thread breakagedetection apparatuses 30 are coupled to the textile sewing apparatus 20.In one embodiment, the thread breakage detection apparatus 30 can beattached or fixed to the textile sewing apparatus using brackets,clamps, or other suitable fixing means.

The system shown in FIG. 2 depicts a thread breakage apparatus 30disposed proximate to each yarn guide plate 25. The placement of theapparatus 30 can include any one or all of the positions disclosed,recognizing that the thread 23 can break anywhere along its path oftravel.

Referring now to FIG. 3, a schematic of a thread breakage detectionapparatus 30 is shown. The thread breakage detection apparatus 30comprises a light source 31, an emitter 32 in communication with thelight source 31, and a receiver 33 in communication with the emitter 32.The terms “communicate” or “communication” mean to mechanically,electrically, optically, or otherwise contact, couple, or connect byeither direct, indirect, or operational means.

Preferably, the light source 31 is an LED (light emitting diode). In oneembodiment, the light source 31 comprises a 4-element red LED.Alternatively, other suitable light sources can be used. The lightsource 31 is operable to generate a light beam. In one embodiment, thelight beam comprises a wavelength in the infrared range. Generally, thelight beam is continuously generated by the light source 31.Alternatively, the light beam can be generated as a series of pulses orpackets of light.

The emitter 32 is operable to emit the light beam. The emitter comprisesan emitter lens 34 and a first fiber optic cable 35. Preferably, theemitter lens 34 comprises a convex lens having an outside diameter ofapproximately 4 millimeters and a length of approximately 8.9millimeters. Preferably, the emitter lens 34 has an effective depth ofapproximately 3.6 millimeters and a spot facing depth of approximately0.9 millimeters.

Although shown in schematic form, in one embodiment, the emitter 32 isdisposed proximate to the yarn guide plates shown in FIG. 2. In anotherembodiment, the emitter 32 is disposed proximate to the needle bar 21shown in FIG. 2. Generally, a distance between a light beam emitted fromthe emitter 32 and a thread disposed in the textile sewing apparatus 20comprises a range between approximately 10 millimeters and approximately25 millimeters. Alternatively, other suitable distances can be used.This distance is generally measured as a perpendicular distance betweenthe longitudinal axis of the light beam (formed by a line between andsubstantially perpendicular to the emitter 32 and the receiver 33) andan individual thread or a plane formed by a plurality of threadsdisposed in the textile sewing apparatus 20.

One such suitable lens includes a model F-4 long distance lensmanufactured by Keyence Corporation of Osaka, Japan. Another suitablelens includes a model E39-F1 long distance lens manufactured by OmronCorporation of Kyoto, Japan. Alternatively, other suitable lenses can beused.

The first fiber optic cable 35 comprises a proximate end 35 a and adistal end 35 b. The proximate end 35 a of the first fiber optic cable35 is in communication with the light source 31. The distal end 35 b ofthe first fiber optic cable 35 is in communication with the emitter lens34. Preferably, the distal end 35 b of the first fiber optic cable 35comprises a light emitting surface (not shown), which is disposedproximate to and in facing opposition to the emitter lens 34. In oneembodiment, the light emitting surface of the first fiber optic cable 35is in communication with the emitter lens 34. In an alternateembodiment, the light emitting surface of the first fiber optic cable 35is coupled to the emitter lens 34. Typically, the light beam emittedfrom the emitter 32 comprises a collimated optical beam (not shown).

The receiver 33 is operable to receive the light beam emitted from theemitter 32 and to communicate the light beam to a sensor 36. Preferably,the sensor 36 is a digital sensor. The receiver 33 comprises a receivinglens 37 and a second fiber optic cable 38. The receiving lens 37 is aconvex lens having the characteristics and features as that describedabove with respect to the emitter lens 34. In one embodiment, thediameter of the receiving lens 37 is substantially equal to or less thana diameter of the thread 23 disposed in the textile sewing apparatus 20.

The receiving lens 37 is disposed in facing opposition to the emitterlens 34. Although FIG. 3 shows the emitter lens 34 and the receivinglens 37 as axially aligned, in practice it is difficult, if notimpossible to axially align the emitter lens and the receiving lens 37.The emitter lens 34 and the receiving lens 37 are not required to beaxially aligned.

The second fiber optic cable 38 comprises a proximate end 38 a and adistal end 38 b. The proximate end 38 a of the second fiber optic cable38 is in communication with the receiving lens 37 and the distal end 38b of the second fiber optic cable 38 is in communication with the sensor36. Suitable fiber optic cables for the first and second fiber opticcables 35,38 include an FU-7F thru-beam fiber optic cable manufacturedby Keyence Corp. Another suitable fiber optic cable includes the E32-TC1000 thru-beam fiber optic cable manufactured by Omron Corp.Alternatively, other suitable fiber optic cables can be used.

Preferably, the proximate end 38 a of the second fiber optic cable 38comprises a light receiving surface (not shown), which is disposedproximate to the receiving lens 37. In one embodiment, the lightreceiving surface of the second fiber optic cable 38 is in communicationwith the receiving lens 34. In an alternate embodiment, the lightreceiving surface of the second fiber optic cable 38 is coupled to thereceiving lens 34.

Generally, the receiving lens is operable to focus the light beam on thelight receiving surface of the second fiber optic cable 38. In oneembodiment, a distance D between the emitter 32 and the receiver 33comprises a range between approximately 1 meter and approximately 4meters.

The sensor 36 is operable to determine a quantity of light received bythe receiver 33. The sensor 36 is in communication with the second fiberoptic cable 38. Preferably, the sensor 36 is coupled to the distal end38 b of the second fiber optic cable 38. In one embodiment, the sensor36 is in communication with a first processor 39. The sensor 36 isadapted to communicate the quantity of light received to the firstprocessor 39. The sensor 36 is operable to generate a signal associatedwith the quantity of light received.

The first processor 39 is in communication with the sensor 39 and thelight source 31. The first processor 39 is further in communication witha second processor (not shown). The second processor is operable tocontrol the textile sewing apparatus 20. In one embodiment, the secondprocessor comprises a relay. In another embodiment, the second processorcomprises a microprocessor, such as for example, a PLC (programmablelogic control) or a PC (personal computer). Other suitable processorscan be used. Alternatively, the first processor 39 is operable tocontrol the textile sewing apparatus 20 directly without communicationto the second processor.

In one embodiment, the first processor 39 is operable to control thelight source 31. For example, the first processor 39 is operable tocontrol an amount and duration of power provided to the light source 31.The first processor 39 is operable to associate a first value with aquantity of light emitted from the emitter 32 and to associate a secondvalue with a quantity of light received by the receiver 33. The firstprocessor is operable to compare the first and second values.

Generally, the amount of light emitted from the emitter 32, and thus thefirst value, is predetermined. The amount of light emitted from theemitter 32 typically is substantially consistent during operation of thethread breakage detection apparatus 30. Of course, the quantity of lightemitted from the emitter 32 is determined by the operational conditionsof the textile sewing apparatus 20, such as for example ambient lightconditions, dust, and vibration.

As discussed above, the first processor 39 is operable to compare firstvalue and the second value. Generally, the first processor stores apredetermined range of second values, which indicate that the light beamhas not been interrupted by a broken thread in the textile sewingapparatus. A range of the second values is set to account for variationin the amount of light received by the receiver 33 and to minimize“false positive” signals—i.e., signals that incorrectly indicate aninterruption of a break in the light beam.

As discussed above, operating conditions can affect the quantity oflight received by the receiver 33, such as for example, ambient lightingconditions, dust, and vibration. Thus, there are no uniform presetvalues for the first and second values. Rather the first and secondvalues must be determined for the unique ambient conditions in which thebreakage apparatus 30 is located.

In one embodiment, the first processor 39 is operable to compare thefirst and second values approximately every 20 milliseconds. The firstprocessor 39 is operable to generate a stop signal associated with thecomparison of the first and second values. Preferably, the firstprocessor 39 generates the stop signal when the second value is outsidethe predetermined range, thus, indicating that the light beam has beeninterrupted by a broken thread. The first processor 39 is operable tocommunicate the stop signal to the second processor. Alternatively, thefirst processor is operable to communicate the stop signal directly tothe textile sewing apparatus 20. In either embodiment, the stop signalis operable to open a main switch (not shown) of the textile sewingapparatus 20, thus halting operation and reducing or eliminating mends.

Although the light source 31, the sensor 36, and the first processor 39are shown as separate, or stand-alone components, they can be housed ina single or integral unit. One such suitable device includes an FS-V21RFiber Optic Amplifier manufactured by Keyence Corp. Another suitabledevice includes an E3X-D11S Fiber Optic Amplifier manufactured by OmronCorp. Alternatively, other suitable systems and components can be used.

Referring now to FIG. 4, a method 40 according to an embodiment of thepresent invention is shown. FIG. 4 shows an embodiment of a method 40 ofdetecting thread breakage in a textile sewing apparatus. The method 40may be employed to detect yarn breakage in a carpet tufting machine, asdescribed above. Items shown in FIGS. 1-3 are referred to in describingFIG. 4 to aid understanding of the embodiment of the method 40 shown.However, embodiments of methods according to the present invention maybe employed to make a variety of other textile sewing apparatuses.

Referring now to FIG. 4, block 42 indicates that the method 40 comprisesproviding a light source operable to generate a light beam. Preferably,the light source generates a light beam as that described above and withreference to FIG. 3. Alternatively, the light source can generate alight beam using other suitable means.

As indicated by block 44, the method 40 comprises providing an emitteroperable to emit the light beam. The emitter comprises an emitter lensand a first fiber optic cable. The fiber optic cable comprises proximateand distal ends. The proximate end of the fiber optic cable is incommunication with the light source and the distal end of the firstfiber optic cable is in communication with the emitter lens. In oneembodiment, the distal end of the first fiber optic cable is coupled tothe emitter lens. The emitter can be as that described above and withreference to FIG. 3. Alternatively, other suitable emitters can be used.

As shown in block 46, the method 40 comprises providing a receiveroperable to receive the light beam and to communicate the light beam toa sensor. The receiver comprises a receiving lens and a second fiberoptic cable. The second fiber optic cable comprises proximate and distalends. The proximate end of the fiber optic cable is in communicationwith the receiving lens and the distal end of the fiber optic cable isin communication with the sensor. In one embodiment, the proximate endof the fiber optic cable is coupled to the receiving lens. Preferably,the receiving lens is disposed in facing opposition to the emitter lens.The receiver can be as that described above and with reference to FIG.3. Alternatively, other suitable receivers can be used.

In one embodiment, the method 40 comprises providing the emitter incommunication with the light source and the receiver. Generally, thereceiving lens comprises a diameter substantially equal to or less thana diameter of a thread disposed in the textile sewing apparatus.Typically, the receiving lens is operable to focus the light beam on asurface of the proximate end of the second fiber optic cable.

In one embodiment, the method 40 further comprises providing a firstprocessor in communication with the light source, the sensor, and thesecond processor. Preferably, the sensor is a digital sensor.Alternatively, an analog sensor can be used. The second processor isoperable to control the textile sewing apparatus. In one embodiment, thesecond processor comprises a relay. In another embodiment, the secondprocessor comprises a microprocessor, such as a PLC or a PC.Alternatively other microprocessors can be used. The first and secondprocessors can be as that described above and with reference to FIG. 3.Alternatively, other suitable processors can be used.

Generally, the first processor is operable to associate a first valuewith a quantity of light emitted from the emitter and to associate asecond value with a quantity of light received by the receiver. In oneembodiment, the first processor is operable to compare the first andsecond values. Typically, the first processor is operable to generate asignal associated with the comparison of the first and second values andto communicate the signal to the second processor. Alternatively, thefirst processor is operable to communicate the signal directly to thetextile sewing apparatus.

The operation of the first processor and its control of the textilesewing apparatus can be as that described above and with reference toFIG. 3. Alternatively, other suitable operation of the first processorcan be used such that thread breakage is detected by the light beam andoperation of the thread sewing apparatus is halted thereafter.

While the present invention has been disclosed with reference to certainembodiments, numerous modifications, alterations, and changes to thedescribed embodiments are possible without departing from the sphere andscope of the present invention, as defined by the appended claims.Accordingly, it is intended that the present invention not be limited tothe described embodiments, but that it has the full scope defined by thelanguage of the following claims, and equivalents thereof.

1. A system comprising: a textile sewing apparatus; and a threadbreakage detection apparatus coupled to the textile sewing apparatus,the thread breakage detection apparatus comprising: a light sourceoperable to generate a light beam; an emitter in communication with thelight source, the emitter operable to emit the light beam, the emittercomprising an emitter lens and a first fiber optic cable comprisingproximate and distal ends, the proximate end of the first fiber opticcable in communication with the light source and the distal end of thefirst fiber optic cable in communication with the emitter lens; and areceiver in communication with the emitter, the receiver operable toreceive the light beam emitted from the emitter and to communicate thelight beam to a sensor, the receiver comprising a receiving lens and asecond fiber optic cable comprising proximate and distal ends, theproximate end of the second fiber optic cable in communication with thereceiving lens and the distal end of the second fiber optic cable incommunication with the sensor, the receiving lens disposed in facingopposition to the emitter lens.
 2. The system of claim 1, wherein thelight beam comprises a wavelength in the infrared range.
 3. The systemof claim 1, wherein the receiving lens comprises a diameter, thediameter substantially equal to or less than a diameter of a threaddisposed in the textile sewing apparatus.
 4. The system of claim 1,wherein a distance between the light beam and a thread disposed in thetextile sewing apparatus comprises a range between approximately 10millimeters and approximately 25 millimeters.
 5. The system of claim 13,wherein the emitter is disposed proximate to the yarn guide plate. 6.The system of claim 13, wherein the emitter is disposed proximate to theneedle bar.
 7. The system of claim 1, wherein a distance between theemitter and the receiver comprises a range between approximately 1 meterand approximately 4 meters.
 8. A method of detecting thread breakage ina textile sewing apparatus, the method comprising: providing a lightsource operable to generate a light beam; providing an emitter operableto emit the light beam, the emitter comprising an emitter lens and afirst fiber optic cable comprising proximate and distal ends, theproximate end of the first fiber optic cable in communication with thelight source and the distal end of the first fiber optic cable incommunication with the emitter lens; and providing a receiver operableto receive the light beam and to communicate the light beam to a sensor,the receiver comprising a receiving lens and a second fiber optic cablecomprising proximate and distal ends, the proximate end of the secondfiber optic cable in communication with the receiving lens and thedistal end of the fiber optic cable in communication with the sensor,the receiving lens disposed in facing opposition to the emitter lens. 9.The method of claim 8, further comprising providing the emitter incommunication with the light source and the receiver.
 10. The method ofclaim 8, wherein the receiving lens comprises a diameter substantiallyequal to or less than a diameter of a thread disposed in the textilesewing apparatus.
 11. A thread breakage detecting apparatus adapted tobe coupled to a textile sewing apparatus, the thread breakage detectingapparatus comprising: a light source operable to generate a light beam;an emitter in communication with the light source, the emitter operableto emit the light beam, the emitter comprising an emitter lens and afirst fiber optic cable comprising proximate and distal ends, theproximate end of the first fiber optic cable in communication with thelight source and the distal end of the first fiber optic cable incommunication with the emitter lens; and a receiver in communicationwith the emitter, the receiver operable to receive the light beam and tocommunicate the light beam to a sensor, the receiver comprising areceiving lens and a second fiber optic cable comprising proximate anddistal ends, the proximate end of the second fiber optic cable incommunication with the receiving lens and the distal end of the secondfiber optic cable in communication with the sensor, the receiving lensdisposed in facing opposition to the emitter lens.
 12. The apparatus ofclaim 11, wherein the receiving lens comprises a diameter, the diametersubstantially equal to or less than a diameter of a thread disposed inthe textile sewing apparatus.
 13. The apparatus of claim 11, wherein thereceiving lens is operable to focus the light beam on a surface of theproximate end of the second fiber optic cable.
 14. The apparatus ofclaim 11, wherein a distance between the emitter and the receivercomprises a range between approximately 1 meter and approximately 4meters.